Monolithic magnetic modules for integrated planar magnetic circuitry and process for manufacturing same

Abstract

Magnetic modules and a process for manufacturing magnetic modules are provided wherein magnetic material is deposited into one or more cavities patterned into a non-magnetic substrate die to form a plurality of magnetic cores. The patterned substrate board, which may be a composite of graphite, a composite of alumina or other non-magnetic ceramic, provides a surface for winding windows, inductor air gaps, isolations, and a mounting surface for other system components.

What is claimed as new and desired to be protected by Letters Patent of the U.S. is:  
     
       1. A magnetic module comprising a magnetic core deposited into a cavity patterned into a non-magnetic substrate board. 
     
     
       2. The magnetic module of  claim 1  wherein a plurality of magnetic cores are deposited into cavities patterned in said substrate board. 
     
     
       3. The magnetic module of  claim 2  wherein said magnetic cores form an outer surface planar with said substrate board. 
     
     
       4. The magnetic module of  claim 2  wherein said magnetic cores are plasma sprayed into said cavities etched in said substrate board. 
     
     
       5. The magnetic module of  claim 4  wherein said substrate board is non-magnetic ceramic. 
     
     
       6. The magnetic module of  claim 4  wherein said substrate board is a composite of graphite. 
     
     
       7. The magnetic module of  claim 4  wherein said substrate board is a composite of alumina. 
     
     
       8. The magnetic module of  claim 4  wherein said cavities are patterned using laser ablation. 
     
     
       9. The magnetic module of  claim 8  wherein said magnetic cores form an outer surface planar with said substrate board. 
     
     
       10. A method for manufacturing a magnetic module comprising the steps of patterning a cavity into a substrate non-magnetic and depositing a magnetic material into said cavity patterned in said non-magnetic substrate. 
     
     
       11. The method of  claim 10  wherein a plurality of cavities are patterned into said substrate and wherein magnetic material is deposited into said plurality of cavities. 
     
     
       12. The method of  claim 11  wherein said depositing step is performed using plasma spraying. 
     
     
       13. The method of  claim 11  wherein said depositing step is performed using spin-on pyrolysis. 
     
     
       14. The method of  claim 12  wherein said magnetic material is a substituted nickel zinc cobalt ferrite. 
     
     
       15. The method of  claim 12  wherein said magnetic material is a substituted manganese zinc cobalt ferrite. 
     
     
       16. The method of  claim 12  wherein said magnetic material has varying permeabilities. 
     
     
       17. The method of  claim 12  wherein the patterning step is performed using ion milling. 
     
     
       18. The method of  claim 12  wherein said patterning step is performed using mechanical machining. 
     
     
       19. The method of  claim 12  wherein said patterning step is performed using laser ablation. 
     
     
       20. The method of  claim 19  wherein said substrate is a non-magnetic ceramic. 
     
     
       21. The method of  claim 19  wherein said substrate is a composite of graphite. 
     
     
       22. The method of  claim 19  wherein said substrate is a composite of alumina. 
     
     
       23. The method of  claim 19  further comprising the step of forming winding holes in said substrate. 
     
     
       24. The method of  claim 23  further comprising the step of applying electrical windings around said magnetic cores.